Ground Wire from Inverter getting hot, I have a few ideas but looking for advice

bigred · July 28, 2017, 04:00:59 PM

Quote from: Jon on July 28, 2017, 03:19:23 AM
I have never heard anyone use 300 amp and 10 Ga wire in the same sentence.

Nope !!! 10 gage is usually around 30 amps

HB of CJ · July 28, 2017, 04:21:36 PM

Solder may not be recommended here. Consider a proper crimp done with the mother of all 6 foot crimping tool, then heat shrink plastic coverings.

Dave5Cs · July 28, 2017, 05:47:42 PM

Jon and Red I didn't say 10 gauge and 300 AMPS in the same statement. if you re read it above guys. I said 300 Amp breaker on the cable from the Magnum 4024 inverter charger Hybrid to the Batteries on the positive cable as per instructions. The ground wire I used 10 gauge wire from the inverters ground clamp to the frame again as per instructions. Sorry for any misunderstanding. Please re read.

Dave

neoneddy · July 28, 2017, 10:02:46 PM

HB this ht I did the first time. I made a good dozen crimps brrwwrrwn rwhrw battery bank and other cables, this is the only one giving me trouble.

belfert · July 29, 2017, 09:27:08 AM

Quote from: neoneddy on July 27, 2017, 12:25:50 PM
Took the bus out a few times now, and my inverter must be pulling more juice as the summer heats up because the insulation on the negative terminal (plastic sleeve) is melting.

Now the odd thing is, the positive side is ambient temp. I use 1/0 gauge wire (thick as my thumb)

I see your profile says you are in Ham Lake, MN. I also live in Ham Lake. I would happy to stop by and see if I can help with your electrical issue. You can send me a PM if you are interested

Iceni John · July 29, 2017, 08:08:45 PM

Quote from: HB of CJ on July 28, 2017, 04:21:36 PM
Solder may not be recommended here. Consider a proper crimp done with the mother of all 6 foot crimping tool, then heat shrink plastic coverings.

It doesn't need to be quite that long! My FTZ 94284 crimper has handles about 3 feet long, and with its adjustable dies makes "gas-tight" crimps on 4/0 cables with no problem. I cut one crimp apart to see how it looked inside, and all the cable's individual strands had fused into a solid mass of copper and were also fused to the lug. For me that's plenty good enough. I checked the temperature of one of my starter cable's lugs immediately after starting, and it wasn't even warm. I think the FTZ is as good a crimper as any busnut will ever need for occasional DIY cable-making. Don't forget also having a good cable cutter - if the cutter mashes the strands or makes a mess of the cable, it won't help having a good crimper.

John

Brassman · July 29, 2017, 10:30:56 PM

Did you take an amp reading of the wire? A ground wire shouldn't have (much) current. A DC clamp-on amp meter is a great tool to have.

gumpy · July 30, 2017, 06:16:22 AM

Quote from: Brassman on July 29, 2017, 10:30:56 PM
Did you take an amp reading of the wire? A ground wire shouldn't have (much) current. A DC clamp-on amp meter is a great tool to have.

I've never been able to find a DC clamp-on amp meter. Only AC.

Oonrahnjay · July 30, 2017, 06:29:07 AM

Quote from: Brassman on July 29, 2017, 10:30:56 PMDid you take an amp reading of the wire? A ground wire shouldn't have (much) current. A DC clamp-on amp meter is a great tool to have.

Quote from: gumpy on July 30, 2017, 06:16:22 AMI've never been able to find a DC clamp-on amp meter. Only AC.

Shouldn't the amps going through a ground wire be well within the range of a "disconnect it and put the meter in line to check the amps" multimeter?

As I mentioned above, it concerns me that a plain chassis ground wire is carrying enough load to heat up the ground wire/terminal connectors.

luvrbus · July 30, 2017, 06:33:48 AM

Quote from: gumpy on July 30, 2017, 06:16:22 AM
I've never been able to find a DC clamp-on amp meter. Only AC.

Craig,a friend sent me a clamp on DC amp meter he found on Amazon

gumpy · July 30, 2017, 06:34:19 AM

Quote from: Oonrahnjay on July 30, 2017, 06:29:07 AM
Shouldn't the amps going through a ground wire be well within the range of a "disconnect it and put the meter in line to check the amps" multimeter? As I mentioned above, it concerns me that a plain chassis ground wire is carrying enough load to heat up the ground wire/terminal connectors.

Yep. Should be. Something's wrong if there's more.

gumpy · July 30, 2017, 06:34:58 AM

Quote from: luvrbus on July 30, 2017, 06:33:48 AM

Craig,a friend sent me a clamp on DC amp meter he found on Amazon

Tell your friend I'll be his friend, too!

bevans6 · July 30, 2017, 07:15:42 AM

AC/DC clamp on meters are almost the norm nowadays, different from only a few years ago. Or so it seems. They seem to be second or third tier of expensive, running around $200 vs under $100 for AC only. I may ask for on for Christmas...

Dave5Cs · July 30, 2017, 02:53:39 PM

Brian, Merry Christmas

https://www.amazon.com/Uni-T-B4Q094-UT210E-Current-Capacitance/dp/B00O1Q2HOQ/ref=sr_1_1/143-7664851-2034502?ie=UTF8&qid=1501451524&sr=8-1&keywords=dc+clamp+on+ammeter

belfert · July 30, 2017, 04:54:37 PM

Quote from: Oonrahnjay on July 30, 2017, 06:29:07 AM
Shouldn't the amps going through a ground wire be well within the range of a "disconnect it and put the meter in line to check the amps" multimeter? As I mentioned above, it concerns me that a plain chassis ground wire is carrying enough load to heat up the ground wire/terminal connectors.

I stopped by his house yesterday since I live in the same city. The cable is the negative cable direct from the battery to the inverter. No connection to chassis ground. I didn't see any issues with anything, but the insulation was melted. He is planning to crimp on a new connector.

I ran a quick voltage drop calculation today and the 1/0 cable seems like it is big enough.